AI-based image processing in the automotive and commercial vehicle sector

Production companies are under enormous pressure today: Customers are demanding more and more variants, delivery times are shrinking, error rates must not increase, and traditional visual inspections quickly reach their limits. Visual quality control is becoming one of the biggest challenges for the manufacturing industry. Every production error costs time, money, and reputation. AI-supported image processing is therefore becoming an indispensable tool for automating inspection processes, efficiently managing product
variants, and ensuring the highest level of quality. The Austrian company Danube Dynamics, together with Aspöck Systems, demonstrates how end-of-line testing of multi-chamber lamps can be efficiently automated. The combination of the AI solution "auros for quality" and IDS camera technology allows even complex inspection tasks in highly varied production environments to be reliably mastered – a solution that offers
immediate added value for companies of all sizes.

Background: More than just "light on, light off" Aspöck Systems manufactures multi-chamber lamps for vehicles, which must be reliably tested at the end of the production line. The decisive factor is not only whether a lamp lights up, but also whether the correct chamber is enabled. A turn signal must not accidentally activate the rear fog light - a mistake that could have serious consequences on the road. Added to this are typical production conditions: different orientations of components, extraneous light in the hall, dust and dirt, and a wide variety of variants. Classic systems based on fixed test rules reach their limits here. Every product change involves a great deal of adjustment work, and unexpected error patterns are difficult to identify reliably.

Solution: AI and camera working together To overcome these hurdles, Aspöck Systems relies on the "auros for quality" solution from Danube Dynamics. At its heart is an adaptive AI that processes image data in real time on a powerful industrial PC (IPC) directly on the line. Image capture is handled by two industrial cameras from the uEye XCP series by IDS. “Our solution does not work with rigid testing rules, but with adaptive algorithms. This enables us to reliably detect even complex or unexpected error patterns and adapt systems to new products very quickly," explains Nico Teringl, CEO of Danube Dynamics. The decision to choose IDS was a conscious one: "In addition to the interface, price, and size, the advice provided by IDS was the decisive factor for us. Together, we found the camera that exactly meets our requirements and guarantees the required precision on a permanent basis," says Nico Teringl.

The role of IDS: Sensor quality meets consulting expertise The IDS U3-3680XCP Rev.1.2 used features the 5.04 MP rolling shutter CMOS sensor onsemi AR0521 and consistently delivers detailed, low-noise images, even in challenging lighting conditions. Back Side Illumination technology ensures high sensitivity and low noise levels, offering a clear advantage in low ambient light or dirty conditions. "The combination of compact size, robust design, and superior low-light 1/4 performance makes this model the ideal component for demanding end-of-line inspections," emphasizes Jürgen Hejna, Product Owner 2D Cameras at IDS. In addition, the IDS peak software environment facilitates the connection of cameras and significantly reduces the integration effort. "Thanks to IDS peak, we were able to get the solution up and running very quickly and integrate it swiftly into the existing production environment at Aspöck," adds Nico Teringl.

From camera to test decision in real time During operation, the multi-chamber lamps are enabled individually by a control system. Two identical IDS cameras capture the images, which are then evaluated on the IPC using AI. The two cameras operate in parallel: While one product is being tested, the next product can already be placed on the test bench. This parallel approach increases cycle time and boosts efficiency. A key advantage of the solution is local processing without the cloud: This guarantees full data sovereignty, high reliability, and minimal latency which is a crucial factor for Aspöck Systems, where production downtime must be avoided at all costs. The solution is independent of the exact alignment of the lamps and robust against environmental variables such as extraneous light or contamination.

The results are displayed in real time on an HMI touchscreen, automatically logged, and can be transmitted to the higher-level production system via an API. This creates a closed inspection process that replaces or effectively supplements manual visual inspections while ensuring complete traceability.

Result: Efficient, flexible, reliable

By combining "auros for quality" with IDS camera technology, Aspöck Systems has taken its end-of-line inspection to a whole new level. Errors are reliably detected under even the most adverse production 2/4 conditions. The system can be adapted to new product variants in just a few minutes via the touchscreen, without the need for time-consuming programming. At the same time, those responsible benefit from clear visualization and digital documentation of the results.

“The support provided by IDS was a decisive factor in our success. Not only did they provide us with the right camera, they also advised us on how to tailor the solution to our requirements”, summarizes Nico Teringl.

Outlook: Quality assurance in transition

Quality control requirements in the automotive sector continue to increase. Inspection tasks are becoming more complex, the required accuracy is increasing, and powerful cameras with AI-supported evaluation are becoming indispensable. "We see a clear trend towards intelligent, AI-supported image processing that is flexible enough to respond to new products and processes without requiring a great deal of effort. That's exactly why we developed 'auros for quality' in combination with IDS camera technology," says Teringl.

Danube Dynamics Embedded Solutions GmbH is a technology company based in Linz, Austria, which has specialized in intelligent embedded system solutions for industry since 2020. The company develops tailor-made solutions at the interface of software, AI and electronics with the aim of driving automation and digitalization forward in an efficient, secure and future-oriented manner through "AI at the Edge". Today, Danube Dynamics has over 30 customers across Europe and employs a team of more than 15 highly qualified developers and engineers. https://www.danube-dynamics.at

Aspöck has been developing innovative LED lighting systems for vehicles since 1977. With a 65% share of the European trailer market and an export quota of 94%, the company supplies resource-saving, efficient, lightweight plastic solutions, including bio-based and biodegradable options. Aspöck is a leader in high quality vehicle lighting solutions for trailers, semi-trailers, superstructures, and the automotive and two wheeler industries. https://www.aspoeck.com/en

About IDS Imaging Development Systems GmbH: IDS Imaging Development Systems GmbH is a leading manufacturer of industrial cameras and pioneer in industrial image processing. The owner-managed, environmentally certified company develops high performance and versatile 2D and 3D cameras as well as models with artificial intelligence (AI) or with streaming/event recording feature. The almost unlimited range of applications covers multiple non-industrial and industrial sectors of equipment, plant and mechanical engineering. Since its foundation in 1997 as a two-man company, IDS has developed into an independent, ISO and environmental-friendly certified family business with around 320 employees. The headquarters in Obersulm, Germany, is both a development and production site. With subsidiaries in the USA, Japan, South Korea and the UK, as well as further representative offices in France, Benelux and India, the technology company has a global presence.